Toner cartridge, contact device and method for developer roller and toner cartridge used therein

ABSTRACT

An image forming apparatus or toner cartridge component thereof uses a bias voltage contact device that fits into an electrobushing which transmits the electrical contact has been invented. Thus, now a bushing can also act as an electrical contact and thereby a spring is not a requirement. The cylindrical bias voltage contact fits into a developer roller and has a smaller portion that is also cylindrical and fits into an electrobushing. The electrobushing is contacted electrically to the power supply of the image forming apparatus. The cylindrical bias voltage contact may have a cylindrical portion that fits into the developer roller by press fit with the new feature where the cylindrical portion has more than one diameter for obtaining a better press fit.

[0001] This application is a Continuation-in-part of Ser. No. 09/613,145filed on Jul. 10, 2000, now U.S. Pat. No. 6,321,048, which issued onNov. 20, 2001, which is a Continuation-in-part of Ser. No. 09/109,309filed on Jun. 30, 1998, now U.S. Pat. No. 6,131,261, which issued onOct. 17, 2000. Even though it is a continuation-in-part, there isactually very little new matter, if any. All new figures added are priorart. In the parent Application, claims were obtained on the arbor presswith extender, including methods. The second Application focused on theimproved toner cartridge, contact device, image forming apparatus andmethods also described in the application. This application will alsofocus on the improved toner cartridge, contact device, image formingaparatus and methods also described in the application. The reason alldevices and methods were entered in the same application is becauseoriginally the Arbor Press, Extender and Methods were invented for thepurpose of press-fitting the contact device of this invention. However,it was found that this Arbor Press, extender and methods were a pioneerpatent in many industries without limit and inventor did not want tolimit it to the imaging industry as it has utility in so manyindustries. This continuation-in-part, however, concerns the improvedtoner cartridge, image forming apparatus, contact device and methodsthereof.

BACKGROUND OF THE INVENTION

[0002] This invention relates to solving problems in Xerography and morespecifically in the toner cartridge remanufacturing industry. Thisincludes copiers, laser printers and facsimile machines which will bereferred to as imaging machines. This invention also relates to theindustrial machinery industry.

[0003] CANON has designed an all-in-one cartridge as seen in U.S. Pat.No. 4,975,744, issued Dec. 4, 1990 and assigned to CANON. Severalcompanies have used these cartridges in laser printers, copy machinesand facsimile machines, each with the varying printer engines and adifferent nameplate. Originally, these cartridges were designed to be“disposable”. However, after the first all-in-one toner cartridge wasintroduced, it did not take long before laser cartridge remanufacturerssuch as myself began remanufacturing these cartridges. These“disposable” cartridges were designed to function for only one cartridgecycle without remanufacturing. The remanufacturers had found certaincomponents that needed replacement on a regular basis. In 1990, thefirst aftermarket photoreceptor drum became available for use inremanufacturing the all-in-one cartridge of the “SX” engine variety, themost popular printer cartridge from around 1987 through 1993. When thelong-life photoreceptor drum became available, the entireremanufacturing industry turned around and gained great strength andbegan a huge growth surge that still continues. In October 1993,HEWLETT-PACKARD, the largest seller of this printer engine using theall-in-one cartridge, entered the cartridge remanufacturing industrywith the “Optiva” cartridge, further increasing the size as well ascredibility of this relatively new industry. However, this relativelynew industry grew from the all-in-one cartridge shortly after its debut.Before the introduction of the long-life drum, sometimes called the“superdrum” or “duradrum”, the SX cartridge would last for around threecartridge remanufacturing cycles at best, since the actual useful lifeof the OEM drum was three cycles. However, the long-life drums got theirnames from the fact that they were designed to last for manyremanufacturing cycles or recharges as they are sometimes called.Typically, the long life drum can last for ten or more such cycles,unlike the typical OEM (Original Equipment Manufacturer) drum. With theadditional developments of drum coatings, originally designed for OEMdrums, the long-life drum may last for many additional cycles. Somecoatings, in theory, were designed to be dissolved and removed from overthe drum surface every 1-3 cycles, so the drum life of the long-lifedrum almost seems limitless.

[0004] However, with photoreceptor drums lasting for many cycles, othercomponents of the cartridge have a tendency to require greaterdurability, a better solution, or a greater life. Also, as the successof these cartridges has skyrocketed, the demand is for cartridges withlonger cycles, so component improvements are significant. Therefore,avoiding natural problems with prevention means must also be implementedfor cartridges of longer life both in longer cycle times and greaternumber of cycles. One good example is the electrical contact used inmany developer rollers of toner cartridge assemblies.

[0005] Inventor was awarded U.S. Pat. No. 5,634,175 and 5,648,838 forelectrical contacts for developer roller assemblies. To properly installan electrical contact from the above patents in the most robust way, onewould want to press-fit the contact into the inner wall of the developerroller. It sounds simple. However, you can not just get an arbor pressand press fit the contacts because arbor presses have a very shortmaximum press-fit height. Most arbor presses look alike, just that someare bigger and more powerful than the others, among the most commonarbor presses. However, a ½ ton arbor press has a 4 inch height and aone ton press is not much higher, a two ton press is not much higher andeven a 5 ton arbor press typically is not very high. To press-fitcontacts into developer rollers, most developer rollers are over teninches long and even an expensive 5 ton arbor press, much greater inweight and power than necessary, is not long enough to press-fit allsizes of developer rollers. In another example, the WX (5Si) developerroller is over 18 inches long and would not even fit in a 5 ton arborpress in the typical case. To solve this problem, inventor has developedan arbor press extender device to lengthen the maximum press length thatan arbor press may press. Thus, with this invention, even a small ½ tonarbor press may be used for press-fitting an electrical contact on along developer roller sleeve. With the extender device of thisinvention, there is no limit in the maximum allowable press length thatmay be pressed with an arbor press, and thus, a small ½ ton arbor presswith the extender device of this invention may press a part of a greaterlength than a large 5 ton arbor press without the extender device ofthis invention which saves a lot of money. An electrobushing will beintroduced that is a bushing for truing rotational motion of a developerroller while at the same time acting as an electrically contactingdevice. This simplifies number of parts and makes a stronger connectionand thus may obsolete the use of spring with contact.

SUMMARY OF THE INVENTION

[0006] Accordingly, it is object of this invention to show an improvedcontact receiving device that not only improves rotational trueness ofdeveloper rollers, but also is a link in the electrical contact'sconnection, thus making improved toner cartridges and improved imageforming apparatuses.

[0007] It is yet a further object of this invention to show an improvedcontact receiving device to improve rotational trueness of developerrollers.

[0008] It is an further object of this invention to show an arbor pressextender device to increase the length that a press-fit may beperformed.

[0009] It is a further object of this invention to show an arbor pressextender with modular fixtures and fixture holders that receive each endof the developer roller including an electrical contact that may bepress-fit.

[0010] It is still a further object of this invention to show an arborpress extender with fixtures that receive each end of the developerroller including an electrical contact that may be press-fit.

[0011] It is yet a further object of this invention to show modularfixtures to fit into fixture holders to allow quick change from one typeof press-fit to be performed to another with minimal set-up time betweenpress-fit styles and sizes.

[0012] It is yet a further object of this invention to show quicksnap-on/snap-off fixtures and fixture holders for quick connect/quickdisconnect of fixtures to fixture holders where fixtures may be heldfirmly in place without falling off the fixture holder using the conceptused in quick connect air hose connections.

[0013] It is yet a further object of this invention to show modularfixture holders and fixtures for press fitting applications that quicklyinstall and uninstall using air-hose quick-connect couplers and nipples.

[0014] It is yet a further object of this invention to show modularfixture holders and fixtures for press fitting applications that quicklyinstall and uninstall using a small piece of hose in the bore of thefixture module to make a tight yet removable quick connection.

[0015] In carrying out this invention in the illustrative embodimentthereof, an arbor press is equipped with an extender device to increasethe maximum allowable part length that may be pressed. This not onlyeliminates the need for using a larger press by allowing a smaller pressto be used for pressing long parts, which also saves money, but someparts which may be too long to fit on a much larger arbor press may nowbe pressed on a small arbor press. Modularquick-connect/quick-disconnect fixtures may be used to fit in fixtureholders for holding firm different types of parts and different stylesof developer rollers which may now be press-fit using this extenderdevice of this invention. With this extender device, even extremely longparts may be press-fit economically which opens new doors forapplications using arbor presses in many industries as a result of thisinvention. Even an adjustable length arbor press extender may be usedfor variable extender length for multiple applications with one extenderdevice. An electrobushing is a bushing that conducts electricity to adeveloper roller in a toner cartridge which is a component of an imageforming apparatus or directly in an image forming apparatus for improvedtoner efficiency, darker print, more even print and an improved system.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] This invention, together with other objects, features, aspects,and advantages thereof, will be more clearly understood from thefollowing description, considered in conjunction with the accompanyingdrawings.

[0017]FIG. 1 is an isometric view of a prior art toner hopper assemblyshowing the breakdown of the developer roller and OEM electricalcontacts and end fittings.

[0018]FIG. 2 is an isometric view of a prior art toner hopper assemblyshowing the breakdown of the developer roller and some aftermarketelectrical contacts and end fittings.

[0019]FIG. 3 is an isometric view of a prior art toner hopper assemblyshowing the breakdown of the developer roller and some aftermarketelectrical contacts.

[0020]FIG. 4 is an isometric view of an end portion of a prior art tonerhopper assembly showing the breakdown of the contact end of thedeveloper roller, some aftermarket electrical contacts and the printercontact.

[0021]FIG. 5 is an isometric view of an aftermarket electrical contact.

[0022]FIG. 6 shows an isometric view of a prior art developer rollersleeve, showing the shaft and inside the contact end of the developerroller.

[0023]FIG. 7 is an isometric view of an aftermarket bushing used toreceive the electrical contact which functions with the electricalcontact to make electrical connection.

[0024]FIG. 8 shows an isometric view of a metal bushing for receivingthe end of a developer roller that prevents wobble, trues rotation andmay optionally act as a link in the electrical contact's connection,shown prior to the press-fit of the aftermarket electrical contact.

[0025]FIG. 9 shows an isometric view of a prior art developer rollersleeve end, showing the shaft, new and improved electrical contact andmetal bushing after the electrical contact is press-fit in place.

[0026]FIG. 10 shows an isometric view of a prior art developer rollersleeve end, showing the shaft, new and improved electrical contact andmetal bushing after the electrical contact is press-fit in place andmetal bushing is in proper position.

[0027]FIG. 11 shows an isometric view of a typical prior art arbor pressthat can be found at most tool supply distributors.

[0028]FIG. 12 shows an isometric view of an arbor press with the newextender added to the arbor press also showing the upper fixture holdermodule.

[0029]FIG. 13 shows an isometric view of an arbor press with the newextender added to the arbor press, also showing the top and bottomfixture holder modules.

[0030]FIG. 14 shows an isometric view of an arbor press with the newextender added to the arbor press, also showing the top and bottomfixture holder modules with a developer and aftermarket contact inplace.

[0031]FIG. 15 is an isometric view of a new and improved aftermarketelectrical contact.

[0032]FIG. 16 is an isometric view of an upper fixture holder.

[0033]FIG. 17 is a cutaway view of an upper fixture holder.

[0034]FIG. 18 is an isometric view of an lower fixture holder.

[0035]FIG. 19 is a cutaway view of an lower fixture holder.

[0036]FIG. 20 is an isometric view of an upper fixture holder with afixture module attached.

[0037]FIG. 21 is a cutaway view of an upper fixture holder with afixture module attached.

[0038]FIG. 22 is an isometric view of an lower fixture holder with afixture module attached.

[0039]FIG. 23 is a cutaway view of an lower fixture holder with afixture module attached.

[0040]FIG. 24 is an isometric view of an upper fixture holder with amale fixture module attached.

[0041]FIG. 25 is an isometric view of a male fixture module.

[0042]FIG. 26 shows a cutaway isometric view of an arbor press with foamin the arbor press opening to prevent the magnetic developer roller fromgetting damaged.

[0043]FIG. 27 shows a cutaway top view of an arbor press with foam inthe arbor press opening to prevent the magnetic developer roller fromgetting damaged.

[0044]FIG. 28 shows an isometric view of an arbor press with foam in thearbor press opening to prevent the magnetic developer roller fromgetting damaged.

[0045]FIG. 29 shows a prior art universal quick connect coupler formaking an air hose connection that is capable of receiving the threequick connect different style nipples in the figure.

[0046]FIG. 30 is a prior art quick connect coupler with male pipethreads at the permanent/semi-permanent connection end.

[0047]FIG. 31 shows a prior art quick connect nipple with male pipethreads at the permanent/semi-permanent connection end.

[0048]FIG. 32 shows a quick connect upper fixture holder using a couplerfor quick connect features.

[0049]FIG. 33 shows a cutaway isometric view of a typical prior artquick connect coupling and nipple used for connection of air hoses.

[0050]FIG. 34 shows a cutaway isometric view of a typical prior artquick connect coupling and nipple used for connection of hydrauliclines.

[0051]FIG. 35 is a digital image showing a cutaway of a typical hosematerial.

[0052]FIG. 36 shows a small piece of hose used to fit in the bore of amodular fixture holder for quick installation and removal of removablefixtures.

[0053]FIG. 37 shows the outside view of an endcap assembly of adeveloper roller assembly showing the printer contact.

[0054]FIG. 38 shows the inside view of an endcap assembly of a developerroller assembly showing the printer contact attached to the ringcontact.

[0055]FIG. 39 is an isometric view of a typical toner cartridge.

[0056]FIG. 40 is an isometric view of a waste toner hopper.

[0057]FIG. 41 is an isometric view of a toner hopper.

[0058]FIG. 42 is an isometric breakdown of a toner hopper and itscomponents.

[0059]FIG. 43 breaks down more components of a toner hopper so that youmay see the components that were covered up inside the toner hopper.

[0060]FIG. 44 shows an isometric cutaway view of a waste toner hopper.

[0061]FIG. 45 shows a typical image forming apparatus.

[0062]FIG. 46 shows an endview cutaway of a typical waste toner hopper.

[0063]FIG. 47 shows a cutaway enlargement of a photoreceptor and adeveloper roller and shows the charging in the typical case and is notto scale.

COMPLETE DESCRIPTION OF THE PREFERRED EMBODIMENT

[0064]FIG. 45 shows a typical image forming apparatus 350 which may beeither a printer, a copy machine or a facsimile machine. Some imageforming apparatuses use a toner cartridge 351 shown in FIG. 39 whileothers have all components built into the image forming apparatus 351.The toner cartridge 351 is typically made up of two components, thetoner hopper 352 and the waste toner hopper 353. FIGS. 40-41 showanother set of toner hopper 362 and waste toner hopper 363. The tonerhopper has a developer roller 364 and a contact 365 and a tank 366. Thewaste toner hopper 363 has a photoreceptor 367, a charge roller and awaste tank 368.

[0065] The toner is attracted from the developer roller 307 to thephotoreceptor drum 308 as illustrated in FIG. 47. The toner 309 iscomposed of black plastic resin bound to iron particles. The developerroller 307 has a magnetic core 10 so the toner particles are attractedto it. As the roller 307 rotates with toner 309 on it, the doctor blade306 controls the thickness of toner on the surface of the developerroller 307. Newer devices use a urethane spreader blade 320 held inplace by being on a metal assembly 321 as shown in FIG. 43. The plastictoner particles receive a negative surface charge by rubbing against thedeveloper roller because the roller 307 is connected to a DC supply. Theelectrostatic charge on the particles attracts the toner 309 particlesto uncharged portions of the photoreceptor drum 308 that have removedcharge from pixels of light. The charged areas of the photoreceptor drumrepel the toner particles. An AC potential on the developer roller 307helps move the toner 309 to the photoreceptor drum 308 at the desireduncharged areas yet helps toner come back to the developer roller 307from charged areas of the drum 8 to improve density and contrast becausethe AC charge alternates.

[0066] The roller 307 has a nonprint region 322 and 323 shown in FIG.43. In this nonprint region 322 and 323, the developer roller 307 issmoother than the toner transport section 312 of the roller 307. Toneris not allowed to adhere to the surface of the roller 307 in thenonprint region 322 and 323. Typically, a felt pad 324 forms asemicircle, partially around the roller 307 and seals off the end of theroller 307 to prevent toner leakage from the assembly 305. The smoothfelt pad 324 keeps the nonprint region 322 of the roller 307 clean orfree of toner and other debris. Also, in some models, a plastic member(not shown) attached to the doctor blade 306 has an extension (notshown) which scrapes toner from the area of the nonprint region 322 and323 of the roller 307.

[0067] In older toner cartridge assemblies like SX, the all-metal doctorblade is charged the same as the developer roller bias, and is on thesame circuit, and similarly the frame of the NX doctor blade is charged.

[0068] It should be noted that the toner transport section 312 of thedeveloper roller 307 cannot be an electrical contact point for tworeasons. First, it has a rough surface, typically etched and sandblastedwith glass beads or other special treatment such as a conductivecoating. Secondly, the section 312 has a continual layer of toner on it.This toner is ready to be transported to the photoreceptor drum.

[0069]FIG. 44 and 46 show another waste toner hopper 401. The wastetoner hopper has a wiper blade 402 or cleaning blade 402 with a sharpcutting edge 403. The waste toner hopper has a tank 404. There is arecovery blade 405, sealing blade 405 or keeper blade 405 that acts as aseal so that as waste toner is scraped into the waste tank 404, thetoner will fall through the opening 406 between the cleaning blade 402and the recovery blade 405. The recovery blade 405 has a pickup magnet407 nearby to pick up any toner that may leak out when the enduserremoves the toner cartridge 351 from the image forming apparatus 350 forany reason.

[0070]FIG. 1 is a broad illustration of the EX toner hopper 10 used inthe HP LASERJET series 4 printer. The developer roller 2 has an end 3from which the magnetic core 4 and magnetic core shaft 1 extend and thedeveloper roller has another end 7. At the opposite end of the developerroller 2 from the magnetic core shaft 1 is the magnetic core shaft 6 andwhich is smaller than the magnetic core 5 in diameter. The prior artinsulative-plastic developer roller contact device 8 fits into the end 3of the developer roller 2. The magnetic core shaft 1 and 6 are unitarywith the magnetic core 5. A white plastic insulative bushing 9 fits overthe end 3 of the roller 2 and the contact device 8. An alignment piece12 (shown in FIG. 2) with an opening aligns the entire connectionrelative to the metal contact plate 14 mounted on the endcap 14 a of thetoner hopper assembly 10 The metal contact plate 14 connects the contactdevice 8 with a printer contact 13, which in turn connects with theprinter's electronic circuitry. The contact device 8 has a wire. At oneend the wire 182 touches and makes contact with the contact plate 14. Atthe other end the wire 183 touches and makes electrical contact with theinner wall of the developer roller 2.

[0071] This is a very poor bias voltage contact system. As a result ofthe poor contact, the printed image lacks quality after the spring wire182 and 183 loses its resiliency, either where the spring wire 182 and183 touches the contact plate 14 or where the spring wire 183 contactsthe inner wall of the developer roller sleeve 2.

[0072] The spring wire is continuous from 182 where it rotates on thecontact 8 and at the same time contacts the contact plate 14 to 183where it contacts the inner wall of the developer roller sleeve 2.Alternately, the spring wire 182, 183 may get insulated either by toneror oxidation from aging, environment and extreme use. The more thecontact device 8 is used, the worse the image gets. Another contributingfactor is the aged and used surface of the developer roller 2. However,the wire 182, 183 deteriorates and gradually the image degrades insteps, however, when this process is combined with the conditions of thedeveloper roller's 2 surface, it is a defective like a shotgun shootingout of two barrels at the same time with multiplying effects. However,the contact from the wire 182 to the metal contact plate 14 is poor inthe first place because wire is thin and also there is not a lot ofspring wire surface area to contact. There is just a small point to makecontact with the ring of the endcap assembly (FIG. 38) and a small point183 to contact the inner wall of the developer roller 2. Consequently,it is an accident waiting to happen. As the spring wire 182 and 183loses resiliency in time, it loses its contact effectiveness. The sameis true where the spring wire 183 contacts the inner wall of thedeveloper roller 2. As time passes and more print cycles are completed,the spring wire 182, 183 loses its resiliency and the integrity of thecontact of the spring wire 182, 183 to the inner wall of the developerroller 2 is detrimentally affected to the point where the print qualityof the image degrades. The contact device 8, and thus the spring wire182 and 183 rotate with the developer roller 2.

[0073]14 The spring wire 182 moves relative to the metal contact plate14. The mechanical motion makes the spring wire 182 even moresusceptible to loss of resiliency, oxidation, dust, toner and wear.

[0074] These problems led to the development of the devices shown inU.S. Pat. No. 5,634,175, and improvement of the contact device for usein the EX toner hopper assembly 10. FIGS. 2 and 3 show the contactdevice 15, the first aftermarket device for the EX toner hopper. Thecontact device 15 comprises a metal bushing with a large diameterportion 19 sized to fit into the end 3 of the developer roller 2 wherethe large diameter portion 19 of the contact device 15 is completelyinserted into the developer roller 2, providing additional electricalsurface area between the contact device 15 and the roller 2.

[0075]FIG. 2 is a broad illustration of how the developer roller contactdevice 15 is connected with the toner hopper assembly 10. In oneoptimized design, the large diameter portion 19 is inserted into the end3 of the roller 2, and the plastic bushing 9 is slipped over the rollerend 3 and contact device 15. The small diameter portion 18 is thenpressed against the coil spring 11 and into the opening 16 in theinsulative alignment piece 20, and the developer roller 2 is mounted onthe toner hopper assembly 10. The contact device optionally may have arim 17. FIG. 3 is an enlarged view of the relevant end of the tonerhopper assembly 10 to more clearly illustrate the contact device 15connection. The alignment piece 20 and coil spring 11 are shownseparated from the assembly 10 for clarity. The outer surface of thelarge diameter portion 19 of the contact device 15 may be adhered byglue or conductive glue to the inner wall of the developer roller 2.However, for best results, a press fit would make the best electricalcontact, much better than gluing the contact. Also by press-fitting thecontact 15, the contact, which in this case also acts as an alignmentshaft, will have a more true rotational motion. The developer roller hasa nonprint region 23 on one end and there is also a nonprint region onthe other end. The magnet core reduces in diameter first at referencenumber 22 and then it reduces further to form a magnet core shaft 21.

[0076]FIGS. 4 and 5 show another contact device 25 from inventor's U.S.Pat. No. 5,634,175 used in the LX toner cartridge. The contact device 25comprises a cylindrical member 26 with a rim 27. The cylindrical member26 has an outside diameter sized to snugly fit inside the end 31 of thedeveloper roller 24. The rim 27 is sized to abut against the end 31 ofthe developer roller when the cylindrical member 26 is completelyinserted within the developer roller 24. The interior of the contactdevice 25 has two portions. The first portion 28, adjacent the rim endof the contact device 25, has an inside diameter sized to slide over thewasher 33 in the printer electrical contact 36. The second portion 29has an inside diameter sized to fit around the end of the magneticcore's shaft 4 within the developer roller 24. A contact surface 30 isformed where the interior portions 28 and 29 meet in a linear direction.The contact surface 30 remains in contact with and rubs against the faceof the washer 33 which is unitary with the projection 35 which connectswith the printer's electronic circuitry within the printer electricalcontact 36 when the developer roller contact device 25 rotates with thedeveloper roller 24. This specific printer electrical contact 36 alsohas an insulative plastic cap 32 and an insulative plastic assembly 34within the printer contact device 36.

[0077] It has been found that the developer roller contact device 25works well, fitting by snugness without adhesive. However, it has beentested using adhesive to adhere the contact device 25 within the end 31of the developer roller 24 and there was no ill effect. When usingadhesive, one must be careful not to create an insulative layer thatwould prevent contact. The only purpose of glue is to prevent thecontact device 25 from spinning within the developer roller sleeve 24which would machine a groove within the roller. Conductive adhesives maybe used. However, it has been found that using a press-fit contact 25eliminates the need for glue, improves the contact and makes for a moretrue rotation of the developer roller sleeve 24. With the developerroller contact device 25, electrical contact with the developer roller24 is maintained not only where the rim 27 abuts against the end 31 ofthe roller 24, but also where the cylindrical member 26 touches theinner wall of the roller 24.

[0078] For any such contacts, a very small amount of conductive greaseshould be applied wherever rotating parts make electrical contact withstationary parts and vice versa. There are two basic types of conductivegreases in the aftermarket, white grease and black grease. Black greasemeasures conductivity with an ohmeter and white grease does not.However, white grease nonetheless performs as well even though it doesnot measure actual conductivity and solves the problems that conductivegrease is there to solve, i.e., stability of contact, prevention ofcontact-loss, arc prevention and corrosion resistance. Inventorintroduced the first aftermarket conductive grease to the tonercartridge remanufacturing industry in an article he wrote that waspublished in Recharger in 1992. Black grease has the major disadvantagethat by the end of a cartridge remanufacture cycle, the black greaseforms a hard layer on the outer surface and thus requires cleaningbetween every recharge cycle. However, hardened black grease does remainconductive when transformed to the hardened solid state. It is becauseof the cleaning requirement of the black grease that is a costlynuisance that has convinced inventor that the black grease is notrecommended and that the white grease is. By the end of a tonercartridge cycle, the white grease is partially gone, thus sacrificiallydoing its job, but does not require any cleanup of components like blackgrease does.

[0079] It has been found that the best manufacture of such electricalcontacts 15 and 25 may be made using a press-fit rather than requiringthe use of a glue. Thus the tolerances must be plus and minus 0.005inches in the typical case in dimensions that involve press fit for theEX developer roller 2. This is the tolerance available in manufacturewithout taking special precautions that would otherwise increase themanufacture costs of the contacts 15 and 25.

[0080]FIG. 6 shows a developer roller 37 of the HP-4000 toner cartridge.The roller has a left side 38, a right side 39, a metal shaft 41, aright side bushing 44, a right side 45 of metal shaft 41, a left andright end 43 and 46 of metal shaft 41 and an inner bore 42. It can beseen in the figure that just to the right of the inner bore 42, the boredimension of the developer roller sleeve 37 is smaller in diameter.Thus, the inner bore 42 is a counter bore in the smaller bore to theright. It is in this inner bore 42 where the plastic OEM contact fits inthe HP-4000 developer roller 37 (not shown). This OEM contact isessentially the same as the EX contact 8 shown in FIG. 1. The OEMcontact 8 rotates in a plastic wearable modular receiving bore assemblynot shown. The problem is that the modular receiving bore assembly madeof plastic can enlarge in bore size and thus cause the developer roller37 to have a slight wobble. This slight wobble would cause the developerroller to have chatter and appear worn prematurely. In other cases, theout-of-round modular receiving bore assembly can cause the developerroller to physically contact the metal of the magnetic endseal (notshown) that replaces the endfelts of old. When the developer rollertouches the magnetic endseal, you can kiss the developer roller sleeve37 goodbye because the metal along the side of the endseal will machinea groove into the soft aluminum developer roller sleeve 37. This isalmost the same as putting the developer roller sleeve 37 on a lathe andhaving a metal tool cut into the aluminum tube 37.

[0081]FIG. 7 shows the electrobushing 47 that is designed to replace theremovable all-plastic OEM receiving bore assembly. It looks similar inshape, but the electrobushing is metal or conductive plastic and themodular receiving bore assembly has different shapes on the outside forfitting into the endcap assembly 173 (FIGS. 37 and 38) with a groove tolock into the endcap assembly 173. The electrobushing 47 was made in asimpler way to decrease manufacturing costs and thus roundness is thekey. However, the electrobushing was made to make contact with the leftend 53 to the printer contact 173 and thus was designed a little longerin length than the OEM plastic bushing. By being a little longer theelectrobushing 47 will make tighter fit of the developer roller 37 inthe toner hopper, but will maintain electrical contact by being tighter.The electrobushing 47 has a rim 49, a left surface of rim 48, or a flatring shaped portion 48, a bore 50, a cylindrical portion 51, a circleportion 52 where the cylindrical portion 51 joins the rim left surface48. The endcap 173 has two holes 178 , to hold it in place, a metal flatspring contact 176 which connects to a contact ring 177, all in onemetal piece. The left end 53 of the electrobushing 47 is longer than theOEM's plastic bushing design so that, unlike the OEM bushing, theelectrobushing left side 53 makes contact with the metal contact ring177 for better electrical contact. The OEM plastic bushing fits insidethe plastic sleeve receiving wall 181 as does the electrobushing 47.

[0082]FIG. 8 shows an exploded view of the electrobushing 47, the newcontact 54 and the developer roller 66. The electrobushing 47 isdesigned not only to prevent the out-of-roundness of the OEM plasticbushing that can cause problems after the inner bore enlarges, but alsohelps the functioning of the contact 15. However, the contact biasvoltage contact 15 has been slightly improved by the bias voltagecontact 54 of, which is designed more optimally for a press-fit. Bothcontacts 15 and 54 are identical except for the two steps 55 and 57shown on the bias voltage contact 54. The contact 54 has a smallerportion 55 (the first step) on the press-fit side, a right end 56, alarger portion 57 (the second step) of the press-fit cylindricalportion, a joining portion 58 where the larger portion 57 joins thesmaller portion 55, a rim 59, a second joining portion 60 where the rim59 joins the larger portion 57, s flat 61 surface of rim 59, analignment portion 62, a bore 63 in the alignment portion, and an endsurface 64 in the alignment portion 62. The press-fit contact 54 has asecond bore (not shown) through the smaller portion 55 and the largerportion 57 that is larger than the diameter of the magnetic core (notshown) on the shaft 41. The press-fit contact 54 is to be press-fit ontothe developer roller sleeve 66 which has an inner bore 42, a left rim68, and a counter bore portion 69 of the inner bore 42. A counterboremay be made in the developer roller sleeve 66 which results in an outerbore portion 69 and an inner bore portion begins at 42 where the innerbore diameter in this example is identical to the original diameter ofthe developer roller sleeve prior to putting the counterbore in it. Itis clearly seen in FIG. 8 that the larger portion 57 of the bias voltagecontact 54 fits in the outer bore portion 69 and the smaller portion 55of the bias voltage contact 54 fits in the inner bore past reference 42where the diameter is smaller. The fit may be any kind of fit desirablefor the application which includes a loose-fit, free-fit, medium fit,snug-fit, wringing-fit, tight-fit, medium-force-fit, heavy-force-fit,shrink-fit, press-fit, interference fit, or any kind of fit whatsoeverwithout limit. There is not limit in what tightness may be used to fitthe bias voltage contact device 54 or any other bias voltage contactdevice in this patent application into the developer roller.

[0083] Please note that for any bias contact device 54, it may also becalled a cylindrical member, flange, double-cylindrical member or anyname whatsoever. Note that with the multi-diameter contact 54, apress-fit or other fit may be achieved in two diameter portions whichadd structural rigidity, more true roundness, a more true fit, a moretrue round developer roller cylinder, better electrical contact, morestable rotation, increased surface-to-surface touching for a betterelectrical contact for a more stable rotation. Note that the contactdevice 54 may be implemented either on the drive side or on thenon-drive side of the developer roller. With the two-diameter step, agreater fit may be achieved with or without the press-fit as even aloose fit may be implemented, although there is no limitation. Ofcourse, if it is used on the drive side, a gear would probably be placedon the small diameter portion, depending on the operating requirementsof the environment.

[0084]FIG. 9 is an exploded view of the electrobushing 47 with respectto the developer roller sleeve 66 with the contact 54 already press-fitinto the developer roller 66. FIG. 10 shows the same as FIG. 9 witheverything in place including the electrobushing 47. The press-fit ofthe contact 54 may be done with a hammer. However, by hammering thecontact 54 into the inner bore 42 of the developer roller sleeve 66 maycause problems. For example, the contact, made of steel, brass or bronzecan cause score and scratch marks into the inner bore 42 of thedeveloper roller sleeve 66 and can cause out-of-roundness of thedeveloper roller sleeve 66. Thus, it is a good idea to press-fit theparts with a press instead of a hammer. The least costly and commonpresses used for press-fits are arbor presses. They are used bymechanics in garages to press-fit bearings and other mechanical fittingsthat require a press-fit. With an arbor press, a tremendous amount ofpressure may be exerted with a very small exertion on the part of theoperator by using leverage and a gear. Although much larger arborpresses exist, the most commonly available arbor presses range from onehalf to five ton pressure rating. Most any tool supply house for themachining industry, tool industry and automotive industry sells arborpresses. Arbor presses are readily available most anywhere in the USAand are relatively inexpensive. Most importantly, arbor presses are moresafe than power driven presses because the operator uses his or her handto increase or decrease the pressure.

[0085]FIG. 11 shows a typical arbor press 70. A typical arbor press 70has a handle 71 for manually exerting leverage pressure, and the handlehas a rubber end 72 at each end. The arbor press 70 has a straight ramassembly 73 with gear teeth 74, a straight non-gear portion 75, a ram76, and a top non-geared portion 82. The typical arbor press containsthe straight ram assembly 73, a cap 77, handle 71, a neck 78, a base 79with a base opening 80, a tightening bolt 81 to attach to the benchwhich goes through a bore (not shown) in the base 79. Prior art FIG. 11shows that the ram guide 200 is attached to the neck 78 of the arborpress 70. The cap 77 is secured to the ram guide 200 using four holdingbolts 204. The cap 77 secures the ram 73 in the ram guide 200. Thetightness of the ram 73 inside the ram guide 200 is controlled by thetightness setting of the cap positioning bolt 203 which may be locked inposition with the cap position lock nut 202. The base or supportstructure 79 has a top 205, a bottom or underside 206, a right side 207and a left side 208.

[0086] All structural portions are thick, especially the base 79 and theneck 78. There is one major flaw in these popular arbor press devices70. The first flaw is that they are heavy. A ½ ton arbor press weighsover eight pounds. The second flaw is that arbor presses are designedfor small parts. If the automotive industry uses the arbor press forpress-fitting bearings, then they don't have to be capable ofpress-fitting long parts. The typical arbor press 70 limits in press-fitlength are from the bottom of the cap 77 to the top of the base 79.However, the maximum part length is shorter yet because the figure doesnot show the metal piece that comes with most arbor presses to cover upthe base opening 80 to enable press-fitting. By removing this metalcover of the base opening, parts may extend down to the workbench togain another 2-3 inches in length of a part to be pressed with an arborpress 70. The only solution prior to this invention was to use adifferent kind of a press or use a larger arbor press. There is a largedifference between a ½ ton arbor press and a 5 ton arbor press in costand weight. There is not a large difference between a½ ton arbor pressand a 5 ton arbor press in length of a part to be pressed. Even so, whyshould a person or a company have to purchase an overpowered arbor pressat great expense to do a small job just because an arbor press is tooshort. It is simply because arbor presses, which are mass produced tokeep costs down, are not designed for applications outside the range ofheight simply because most users of arbor presses do not need to press along part. Those that need to press a longer part are in the minorityand must find an alternative that is not an arbor press. Inventor didnot find an alternative, but instead made an extender device thatattaches to an arbor press to increase the length of a part that may bepressed with an arbor press. However, the extender device 83 may also beinstalled in brand new arbor presses, or even cast into the arbor pressand is not limited just what is described in this invention.

[0087]FIG. 12 shows an arbor press with an extender assembly 83 used toincrease the length of parts that may be pressed. The extender assembly83 has a right leg 84 and a left leg 85, optionally a fixture attachbore 87 which may optionally be threaded, a base 86, a left bend 91, aright bend 90, and two attach holes 88 and 89. Alternately, and extenderassembly may be made with multiple sets of attach holes 88 and 89 tomake an extender assembly 83 with multiple length settings. The holesmay be replaced with one or more slots that can be used to adjust theheight of the extender. Holes are drilled and tapped into the base 79 ofthe arbor press 70 at holes 88 and 89 to enable the bolting attachmentof the extender assembly 83 to the arbor press 70. There is an upperfixture holder module 92 on the ram 76 of the arbor press for attachingfixtures that position the parts to be pressed to insure that the pressfit will be straight and proper. FIG. 13 shows the same modified arborpress with a lower fixture holder module 94 for holding a variety offixtures for different applications, also to insure that the press fitwill be straight and proper, used in tandem with the upper fixtureholder module 92. Also shown in the figure is a inner surface 93 of thebase opening region 80.

[0088]FIG. 14 shows a laser printout of a digital image of the arborpress 70 with the extender assembly 83, the upper and lower fixtureholder modules 92 and 94, a developer roller 2, and a press-fit contact54 being press-fit. FIG. 15 shows a laser printout of a digital image ofthe press-fit contact 54 that is used in FIG. 14 because this contact 54is difficult to see in FIG. 14. This figure shows that even though theupper fixture holder module 92 and the lower fixture holder module 94are meant to hold modular fixtures to firmly hold parts to be press-fitat top and bottom, the fixture holder modules 92 and 94 may also be usedas fixtures as in FIG. 14. By causing the fixture holder module to bebased on a widely used size, then all the fixture holders can fit intothat size to economize on the number of fixtures required to fit intothe fixture holders. Different embodiments of these fixtures will laterbe described.

[0089] The extender assembly 83 is actually very simple. Some of thebest pioneer inventions are simple. The extender assembly 83 iscomprised of flat bar cold rolled steel flat bar ⅜ inches thick and 1and ¾ inch wide. The extender 83 has two right angle bends at 90 and 91.Other dimensions would also work. However, inventor will manufacturethis with the above dimensions for strength purposes but does not wantto limit invention to these dimensions. The extender assembly 83 shouldfunction properly with almost any dimensions as long as it increases thelength of a part that an arbor press can press.

[0090]FIG. 16 and 17 show the upper fixture holder module 92 which has asmall bore 95, a larger bore 96, a top 97, a bottom 98, a bore joiningdisk region 99, a top 100 of the smaller bore 95 and a bottom 101 of thelarger bore 96. This fixture holder may be bolted through the bores 95and 96 to the ram 76. It is easiest to use a bolt that may be tightenedwith an ALLEN wrench, the ALLEN wrench made to fit into the larger hole96 to allow turning the bolt. Optionally, the small bore 95 may betapped, however, it is easier to drill and tap a bore into the ram 76 toattach the upper fixture holder module 92.

[0091]FIG. 18 and 19 show the lower fixture holder module 94 which has asmall bore 102, a larger bore 103, a top 104, a bottom 105, a borejoining disk region 106, a bottom 108 of the smaller bore 102 and a top107 of the larger bore 103 This fixture holder may be bolted from belowthe bottom 105 into the small bore 102, preferably threaded as shown inFIG. 19. The small bore 102 may be tapped to attach the lower fixtureholder module 94 to the base 86 of the extender assembly 83 on an arborpress 70.

[0092]FIGS. 20 and 21 show the upper fixture holder module 92 with anupper fixture 111 attached from the bottom 98 of the upper fixtureholder module 92. A bolt 109 is shown to attach the upper fixture module92 to the ram 76. The fixture 111 has a bore 112 to receive the end ofany parts to be press-fit. The bore 112 has a bottom 113 where thepress-fit part may be inserted. When the press-fit part is steel orother material that is attracted by a magnet, the fixture 111 may bemade magnetic so the press-fit part can stay in by magnetism. One way todo this is to make the fixture 111 of steel and to magnetize it althoughthe same may be done by using magnetite or magnetic steel. The fixture111 has an upper fixture stem 114 and the stem 114 has a top 115. Thefixture has a base 117 and a stem join base region 116, and a bottom 118of the base 117. It is not just that the bore 112 is designed to “fitparts” as earlier stated, but some parts to be pressed may haveprotrusions that stick out and the bore 112 is designed to accommodatethese protrusions as well as make a nice fit.

[0093]FIG. 35 shows a typical rubber hose material 165. In this figureit has three layers 166, at the outer layer, 167 in the middle layer and168 at the inner layer. FIG. 36 shows a hose 169 cut to length anddesigned to go into the larger bore 96 of the upper fixture holdermodule 92. With this hose positioned tightly in the larger bore andoptionally glued, upper fixtures 111 may be quickly slipped in the bore172 of the hose 169 by placing the stem 114 of the upper fixture 111snugly in the hose's 169 bore 172 to fit snugly into the inner wall 179.The hose 169 has a bottom 170, a top 171 and an outer surface 180. Thisupper fixture 111 may be quickly installed and uninstalled whendifferent fixtures 111 which are used for press-fitting different partsare required.

[0094]FIGS. 22 and 23 show the lower fixture holder module 94 with alower fixture 119 attached to the top 104 of the lower fixture holdermodule 94. A bolt 110 is shown to bolt the lower fixture module 94 tothe base 86 of the extender assembly 83. The fixture 119 has a bore 120to fit the end of any parts that stick out to be press-fit. The bore 120has a top 121 where the press-fit part may be inserted. When thepress-fit part is steel or other material that is attracted by a magnet,the fixture 119 may be made magnetic. One way to do this is to make thefixture 119 of steel and to magnetize it although the same may be doneby using magnetite or magnetic steel. This might not be necessary sincegravity will hold the component in, but it is an option. The fixture 119has a lower fixture stem 122 that fits into the large bore 103 of thelower fixture holder module 94 and the stem 122 has a bottom 123 Thefixture has a top 126 and a stem join base region 124 and an outersurface 125.

[0095] The hose 169 may optionally fit in the larger bore 103 of thelower fixture holder in order to have a quick install and uninstall forthe lower fixture 119 for changing fixtures quickly and effortlesslywhen press fitting different sized fixtures, for example, on amanufacturing production line. This is certainly quicker than boltingand unbolting components. Any type of hose may be used in thisembodiment or other embodiments using hose. Single layer hose may beused, multilayered hose may be used, and any hose may be used, so longas it protects the surface of the developer roller 2 from scratching orother damage. For example, some of the hose materials that may be usedare rubber, urethane, urethane rubber, air hose, water hose, coolinghose, automotive hose, air conditioning hose, compressed air hose,fishtank tubing, garden hose, hydraulic hose, neoprene rubber, hardrubber, soft rubber, closed cell foam, open cell foam, among many otherhoses, tubes, rubber pipe, molded rubber or extruded rubber. There is nolimit in possibilities in types of hoses and tubing to use for the quickconnect feature in this and other embodiments. Please note that inventorinvented a quick connect lathe adapter set for quickly installing anduninstalling lathe adapters for quick connect shown in U.S. Pat. Nos.5,309,200 and 5,381,213.

[0096]FIGS. 24 and 25 show an upper fixture holder module 92 with anupper fixture 127 attached from the bottom 98 of the upper fixtureholder module 92. A bolt 109 (not shown) may be used to bolt the upperfixture module 92 to the ram 76. The fixture 127 may optionally have abore 129 to attach to the fixture holder 92 with a bolt or otherfastener. The fixture 127 has a bottom 184 to be inserted into thepress-fit part. For example, this is a male fixture 127 as opposed tothe female upper fixture 111. The male fixture 127 may be used topress-fit a component that is female such as the contact 25 shown inFIGS. 4 and 5. The bottom 184 of the fixture 127 inserts into thecontact's 25 first portion 28 and abuts against the contact surface 30of the contact 25 which allows the male fixture 127 to press-fit thecontact 25. The same is true of this fixture for any female object to bepress-fit in any industry whatsoever and is not limited to the imagingindustry. When the press-fit part is steel or other material that isattracted by a magnet, the fixture 127 may be made magnetic so thepress-fit part can stay in by magnetism. One way to do this is to makethe fixture 127 of steel and to magnetize it although the same may bedone by using magnetite or magnetic steel. The fixture 127 has an upperfixture stem 129 (top portion) which has a top 131. The fixture has abase 184 and a stem join base region 130. Although the male fixture 127is shown as an upper fixture, there could also be a lower male fixturedesigned the same way but upside down and it would have all the samefeatures, and thus it is hereby incorporated in this patent applicationby having described the upper fixture 127 to save space. Similarly, theupper fixture 127 may be installed using a hose on the inside bore ofthe fixture holder 92 and/or 94 so the fixture 127 may be installed anduninstalled quickly into either fixture holder 92 or 94.

[0097]FIG. 26 shows an isometric cutaway view of the arbor press. Whenpress-fitting developer rollers are placed in the narrow base opening 80as in FIG. 14, since many developer rollers 2 are very magnetic bydesign, there is a tendency for the outer surface of the developerroller to strongly attract to the base 79 of the arbor press 70 at theinner surface 93 of the base opening region 80. It is this attractionthat can easily score the sensitive surface of the developer roller 2and cause a print defect. For this reason, some soft material 133 isinserted inside the base opening 80 to prevent damage to the developerroller 2. Many soft materials 133 may be used, for example, ester opencell foam, ether open cell foam, any open cell foam, closed cell foam,foam, rubber, foam rubber, cloth, cotton, fabric, wool, polyurethane,polyurethane foam, any open cell material, any closed cell material, anysoft material, any cushiony material. If the poles are known on thedeveloper rollers, like poled magnets may be used in place of the softmaterial 133 to repel the developer roller from touching the baseopening 80. FIG. 27 shows a cutaway top view of the arbor press with thesoft material 136 installed to protect the developer roller 2. Softmaterial 136 may be installed as the figure shows right side softmaterial 135 and left side soft material 134 in the opening 80 of thebase 79 of the arbor press 70. FIG. 28 shows the arbor press 70 with theextender 83 and the installed soft protective material 133, in this caseopen cell ester foam. I like the ester foam best because my daughter'sname is Esther.

[0098]FIG. 29 shows a prior art quick connect universal coupler 137, andthree different quick connect nipples from the air hose (compressed air)industry. The three quick connect nipples are references 138, 139 and140, each one different. The universal coupler 137 may be used by any ofthe nipples 138, 139 or 140, even though each nipple has a completelydifferent design as seen in FIG. 29. There are many more designs ofcouplers too numerous to mention which are to be incorporated in thisinvention even though they are not all shown.

[0099]FIG. 30 shows a typical quick connect coupler 141, different fromthe one previously shown. The quick connect coupler 141 has a male pipethread 142 which is more suitable to the application of using a coupler141 to replace the upper and lower fixture holders 92 and 94. By using acoupler 141 with a male thread 142, the coupler would install into thethreaded bore 87 in the base 86 of the extender 83. By simply replacingthe lower fixture holder module 94 with a coupler 141, a different quickconnect embodiment may be made. The same is true of the upper fixtureholder module 92. The coupler assembly 141 may also replace the upperfixture holder module 92 in the ram 76 of the arbor press 70 and thecoupler assembly 141 may instead be installed in a hole drilled andtaped in the ram 76. In order to use the couplers 137 or 141 as eitherupper or lower fixture holders, the upper and lower fixtures 111 and 119must have a hole drilled and tapped in them to receive the male threads149 of a nipple 148 as shown in FIG. 31. The nipple 148 has a male pipethread to allow the nipple to screw into a tapped hole in a quickconnect fixture 156 as shown in FIG. 32. Please note that the figuresshow that the nipple 148 has a male thread 149, a hex wrench turnportion 150, a bottom end 151, a bottom bore 152, a top end 153, a topbore 154 and a nipple push lock 155. The coupler 141 has a male pipethread 142, a thread end 143, a quick connect end 144, a hex-wrench turnportion 145, a sliding ring 146 and a bottom bore 147. The quick connectfixture 156 of FIG. 32 may be used either as an upper or lower fixtureand has a first lower bore 157 and a second upper bore 158. The fixture156 can quickly connect and disconnect from an upper or lower fixtureholder 141 coupler (not shown in an arbor press), and a user can acquirea set of fixtures similar to 156, each of a different size and quicklyplug them in and out of coupler fixture holders such as 141 located inan arbor press 70 ram 76 or on the threaded hole 87 of the base 86 of anextender 83 for quick changeover on a production line or any workenvironment.

[0100]FIG. 33 shows a cutaway isometric view of a quick connect coupler137 and a quick connect nipple 138. Shown in the figure on the nipple138 is the hex wrench turn portion 150, the top end 153, the bore 154 inthe top 153 and the nipple push lock 155. Shown in the figure on thecoupler are the precision seal 159 and the knurl 160 for easy gripping.Of course, since the couplers are not used 2 for a compressed air hose,the precision seal is not necessary. To use an existing coupler andnipple that is already equipped with unnecessary features relating to apneumatic compressed air line does not hurt the performance of using thequick connect coupler and nipple solely for the quick connect features.FIG. 34 shows a cutaway isometric view of a coupler 162 and a nipple 161from the hydraulic industry, used to quickly connect hydraulic lines.The hydraulic coupler 162 and nipple 161 may also be used similar to thepneumatic coupler 137 and nipple 138 as already described. The hydrauliccoupler 162 has a ball locking mechanism 164. The hydraulic nipple 161has a nipple push lock 163 to secure the nipple 161 into the coupler162.

[0101] Since minor changes and modifications varied to fit particularoperating requirements and environments will be understood by thoseskilled in the art, the invention is not considered limited to thespecific examples chosen for purposes of illustration. The inventionincludes all changes and modifications which do not constitute adeparture from the true spirit and scope of this invention as claimed inthe following claims and as represented by reasonable equivalents to theclaimed elements. Any ideas shown in any embodiments may be incorporatedinto any other embodiments. Any prior art disclosed may be incorporatedwith any embodiment disclosed.

What is claimed is:
 1. An improved electrical connection device for usein an image forming apparatus comprising of a printer, copy machine or afacsimile machine or a toner cartridge used therein to supply a biasvoltage to a developer roller whereby a bias voltage contact fits intothe developer roller; and whereby said bias voltage contact has a firstportion that fits into the developer roller; and whereby said biasvoltage contact has a second portion which is cylindrical and of asmaller diameter than said first portion; and wherein the developerroller has a counterbore and therefore has a larger diameter bore regionand a smaller diameter bore region and said larger portion of said firstportion of said bias voltage contact fits into the larger diameter boreregion while said smaller diameter portion of said first portion of saidbias voltage contact fits into the smaller diameter bore region.
 2. Animproved electrical connection device as in claim 1 wherein said firstportion of said bias voltage contact press-fits into the developerroller.
 3. An improved electrical connection device as in claim 1wherein said first portion of said bias voltage contact fits looselyinto the developer roller.
 4. An improved electrical connection deviceas in claim 1 wherein a spring makes electrical contact between saidsecond portion of said bias voltage contact and a power supply of theimage forming apparatus.
 5. An improved electrical connection device asin claim 1 wherein a spring makes electrical contact between said secondportion of said bias voltage contact and a contact ring in the endcap ofthe toner cartridge.
 6. An improved toner cartridge used in an imageforming apparatus comprising of a dry toner style printer, copy machineor facsimile machine; whereby said toner cartridge comprises of a tonerhopper and a waste toner hopper; and whereby said waste toner hoppercomprises of a photoreceptor, a cleaning blade, a charging device forelectrostatically charging said photoreceptor and a container to receivewaste toner; and whereby said toner hopper comprises of a storage tank,an endcap and a developer roller; and whereby a bias voltage contactfits into said developer roller; and whereby a first portion of saidbias voltage contact has a region that is cylindrical in shape that fitsinside said developer roller and has electrical continuity with an innerwall of said developer roller; and wherein said developer roller has acounterbore and therefore has a larger diameter bore region and asmaller diameter bore region and said larger portion of said firstportion of said bias voltage contact fits into said larger diameter boreregion while said smaller diameter portion of said first portion of saidbias voltage contact fits into said smaller diameter bore region for abetter fit and better electrical connection with inner wall of saiddeveloper roller; and wherein said bias voltage contact device has asecond portion smaller in diameter than said first portion.
 7. Animproved toner cartridge as in claim 6 wherein said first portion ofsaid bias voltage contact press-fits into said developer roller.
 8. Animproved toner cartridge as in claim 6 wherein a spring makes electricalcontact between said second portion of said bias voltage contact and thepower supply of the image forming apparatus.
 9. An improved tonercartridge as in claim 6 wherein a spring makes electrical contactbetween said second portion of said bias voltage contact and a contactring in said endcap of said toner cartridge.
 10. An improved imageforming apparatus comprising of a dry toner style printer, copy machineor facsimile machine; whereby said improved image forming apparatusmakes an image on media; where media may be paper, overhead slide media,microfilm, plastic, labels, cardboard, disk labels, CDROM labels or anydry toner printable media used with a xerographic imaging device;whereby said improved image forming apparatus contains a toner storagecontainer, a waste toner hopper, a photoreceptor, a cleaning blade, afuser section, a photoreceptor charging device and a transfer section;whereby said toner storage container has a storage tank, an endcap and adeveloper roller; whereby a bias voltage contact fits in one end of saiddeveloper roller; whereby said bias voltage contact has a first portionthat fits inside said developer roller and has electrical continuitywith an inner wall of said developer roller; whereby a second portion ofsaid bias voltage contact has a portion that is cylindrical in shape;and wherein said developer roller has a counterbore and therefore has alarger diameter bore region and a smaller diameter bore region and saidlarger portion of said first portion of said bias voltage contact fitsinto said larger diameter bore region while said smaller diameterportion of said first portion of said bias voltage contact fits intosaid smaller diameter bore region for a better fit and better electricalconnection.
 11. An improved image forming apparatus as in claim 10wherein said first portion of said bias voltage contact press-fits intosaid developer roller.
 12. An improved image forming apparatus as inclaim 10 wherein said first portion of said bias voltage contact has aloose-fit into said developer roller.
 13. An improved image formingapparatus as in claim 10 wherein a spring makes electrical contactbetween said second portion of said bias voltage contact and a powersupply of said improved image forming apparatus.
 14. An improved imageforming apparatus as in claim 10 wherein a spring makes electricalcontact between said second portion of said bias voltage contact and acontact sing in said endcap.
 15. A method of making an improved imageforming apparatus comprising of a dry toner style printer, copy machineor facsimile machine; and whereby the improved image forming apparatusmakes an image on media; and whereby media may be paper, overhead slidemedia, microfilm, plastic, labels, cardboard, disk labels, CDROM labelsor any dry toner printable media used with a xerographic imaging device;and whereby said method involves manufacturing an improved image formingapparatus which has a toner storage container, a waste toner hopper, aphotoreceptor, a cleaning blade, a fuser section, a photoreceptorcharging device and a transfer section; whereby the toner storagecontainer has a storage tank, an endcap and a developer roller; wherebythe developer roller has a developer roller sleeve; and whereby saidmethod involves a step of placing a bias voltage contact in one end ofthe developer roller sleeve; whereby the bias voltage contact has afirst portion that fits inside the developer roller sleeve and haselectrical continuity with an inner wall of the developer roller sleeve;whereby a second portion of the bias voltage contact has a portion thatis cylindrical in shape; and whereby said method involves another stepof making a counterbore in the developer roller sleeve whereby thedeveloper roller sleeve has a larger diameter bore region and a smallerdiameter bore region and the larger portion of the first portion of thebias voltage contact fits into the larger diameter bore region while thesmaller diameter portion of the first portion of the bias voltagecontact fits into the smaller diameter bore region for a better fit andbetter electrical connection.
 16. A method as in claim 15 wherein saidmethod involves a step wherein the first portion of the bias voltagecontact press-fits into the developer roller.
 17. A method as in claim15 wherein said method involves a step wherein the first portion of thebias voltage contact has a loose-fit into the developer roller.
 18. Amethod as in claim 15 wherein said method involves a step wherein aspring electrically connects the second portion of the bias voltagecontact to the power supply of the improved image forming apparatus. 19.A method as in claim 15 wherein said method involves a step wherein aspring electrically connects the second portion of the bias voltagecontact to a contact ring in the endcap of a toner cartridge.